stanley cobotics brochure

Assembly Technologies®

TM

NEW SOLUTIONS INMATERIAL HANDLING

TM

www.StanleyAssembly.com2

A New Solution

Stanley Assembly Technologies, a ProductGroup of The Stanley Works, provides solutionsto the industrial assembly market, including themotor vehicle industry. Core solutions includehigh-performance DC electric and pneumatictightening tools and controllers, conventionalpneumatic articulating arms, torque tubes andnow Intelligent Assist Devices for ergonomicmaterial handling.

With our Cobotics product line, Stanley is aleader in the growing market for Intelligent AssistDevices (IADs). Engineered to dramaticallyimprove the productivity, quality and ergonomicsafety of assembly operations, IADs arecomputer controlled, servo powered lift assistdevices that assist workers in lifting andmanipulating heavy and awkward parts.

Proven Technology & Experience

With more than 40 years of experience inproviding engineered solutions Stanley has theexpertise to tackle your most challengingmaterial handling needs. By combining standardproducts such as manipulator arms and endeffectors with cutting edge Intelligent AssistDevice (IAD) technology Stanley offers acomplete range of ergonomic lift assist solutionsideal for any industrial environment. Ourengineers are experts in evaluating customerneeds and converting them into solutions thatimprove the productivity, ergonomics, and qualityof your manufacturing operations.

Complete materialhandling solutions

Technical Support

Designed to boost the bottom line.

As a supplier to the assembly market, Stanleyhas developed a global sales and servicenetwork to support the manufacturing operationsof our customers. Stanley offersmany levels of customer support from basicmaintenance & operator training to full servicerepair facilities and maintenance servicecontracts.

Stanley material handling solutions are designedto improve your operations by:

Increasing Productivity

Improving Quality

Enhancing Ergonomics

Error Proofing Tasks

•

•

•

•

www.StanleyAssembly.com

Arms Rail Systems

Torque Tubes &Vertical Balancers End Effectors

From basic componentsto intelligent systems

Assembly Technologies


Introducing Cobotics,

the next generation

in Material Handling

Intelligent Assist Devices (IADs) enabletrue collaboration of a human operator withcomputer-controlled machinery to provideload movement with greater speed and

control than ever before possible.IADs greatly enhance traditional materialhandling methods with intelligent motioncontrol that optimizes lifting, guiding, andpositioning movements. With a human-machine interface that feels natural andtransparent, IADs increase productivitywhile reducing harmful forces on theoperator's body. Virtual guiding surfacescan further improve the speed and smoothmovement of loads, for reduced partdamage and higher quality.

Many companies have increasedproductivity by as much as 70% usingIADs. These companies are replacingtheir traditional assist devices with IADs,resulting in increased line speeds whilereducing cumulative trauma injuries andimproving quality.

Material handling solutions thatwork harder smarter.and

Axle SequencingTransfer from rack to sequencing cart

Improve Ergonomics Increase Productivity

Reduce labor costsImprove Quality

Catalytic Converter Test CellTransfer between multiple operations

Instrument Panel HandlingTransfer to shipping rack

Cockpit InstallPrevents collision with vehicle

Intelligent Assist Devices

www.StanleyAssembly.com 5

Cobotics IAD components canbe used in combination withtraditional Stanley materialhandling solutions to enablecomplete adaptability to thedemands of your application.

The industry's highest performancelifting and balancingsystem, offering highlyintuitive lift assistancewith a patented floatmode. The iinterfaces withinterlocks andactuators onend effectors,and allowsindividualized

responsiveness profiles.

Unequaled speed and ease in loadpositioning for rigid and cable based

systems on bothmonorails and bridgecranes. Providing easymounting with allconventional railprofiles (both new andexisting installations),quick programmabilityfrom its central hub,semi-automation, andmuch more, the

i helps get the highestperformance and productivity fromoverhead rail systems.

Lift

Trolley

®

Flexible ConfigurationOptions

At the heart of every Stanley CoboticsIAD is leading edge controltechnology that enables the operatorand IAD to work in tandem-for swift,smooth, and precise movements.

Cobotics IADs use "intent sensors"(patent and pending) toquantify the speed and direction ofthe motion that the operator requires.Proprietary algorithms then direct themovement of the IAD.

patent

This advanced control system with closedloop feedback allows the IAD to adjust tochanges in load mass and operator intent.By masking the friction and inertia of theoverhead support structure andeliminating overshoot, the operator canfocus on the payload - rather than theassist device.

Cobotics is the IAD Pioneer

As the founders of IAD technologyin 1995, Stanley offers unmatchedexperience and applicationsexpertise in the field.

We provide:

The Stanley Cobotics family of IADproducts can be combined to create multi-axis solutions. Configurable for specificapplications, these reliable systems utilizeproven servo technology for superior,lasting performance.

Stanley offers both IAD componentsales as well as turn key IADmaterial handling solutions,including rail system and endeffector design/installation. Withover 40 years experience ofimplementing assembly solutions,Stanley is positioned to supportthe global assembly market.

With our sales, service, and distributionnetwork, we provide installation supportand troubleshooting. We also offer trainingprograms for systems integrators.

Multi-Axis IAD Components

IAD System Solutions

Integration support and training

The Cobotics Control Advantage.

®

™


Intelligent Lifting & Balancing

Having trouble

meeting productivity

goals?

Does your lift

equipment slow

you down?

Are upper extremity

strains and injuries

increasing in

your plant?

Would you like

to enhance the

functionality of your

end effector?

Intuitive Control Provides Fast, Precise MovementStanley’s i , the most advanced lifting and balancing system available, allows operators to manipulate loads withgreater speed and precision than ever before. By simply grasping the slide handle or the load itself and gently applyingforce in the desired direction, the operator can manipulate payloads as if they weighed ounces.

Operators can meet productivity goals while reducing ergonomic strain, with programmable virtual limits, user-selectableoperating profiles, and vertical speeds up to 295 ft/min (1.5 m/sec). Offering a blend of power assist and hands-on (“floatmode”) load positioning, the i combines computerized control with human manipulation.

The i maximizes the capability of end effectors—with a programmable hub featuring internal logic for control of endeffector functions via air cylinders, interlocks, proximity switches, and a locally mounted E-Stop.

Allowing easy installation on existing or new rail configurations, quick programmability, and semi-automation, the i isthe highest performing lift assist available today.

Lift

Lift

Lift

Lift

Installation on existing or new railsfrom all major rail manufacturers.

Load Cellwith SwivelAttachment

User Profile SelectionOperators select systemsensitivity.

SystemStatus

SerialProgramming Port

Float ModeEnable Button

SystemStart Button

HubProgrammable central hubis like a mini PLC, providingprogrammable I/O for endeffector functions as wellas a PC or PDA connectionfor system configuration.

Auxiliary Buttonwith ProgrammableFunctionality

Slide HandleAllows easy, power-assistedup-down movements.Operators simply grasp andgently pull up or down. Canbe remote mounted formaximum flexibility.

System Stop

Virtual LimitsConstrain liftmovement betweenvertical boundaries,preventing overtravel.

Optional Pendant HandleLow-effort proportional controlbuttons for precise up/downmovement of awkward orhard-to-manipulate loads.

®

®

®

Optional remote slide handleavailable for end effector integration.

Float StartStop


i Specifications 150 lb. 500 lb.Lift

150 lbs. 500 lbs.

68 kg. 226 kg.

295 fpm 137 fpm

1.5 m/s 0.7 m/s

1 G 0.5 G

9.8 m/s/s 4.9 m/s/s

120 in. / 3048 mm

Continuous (>H5)

120 V AC 220 V AC

1 Phase 1 Phase

15 amps

1/8 in. 3/16 in.3.18 mm 4.76 mm

71 lb. 133 lb.32.2 kg 60 kg

12 V 3 amps

3 digital, 3 analog

2 digital, 1 Interlock, & 1 E-Stop

Capacity:

Maximum Lift Speed:

Acceleration:

Vertical Travel:

Duty Cycle:

Power Requirement:

Max. Current Draw:

Wire Rope Diameter:

Unit Weight:

Hub Power Available:

Hub Inputs:

Hub Outputs:

Flexible Configurations

Benefits

Trolley or rail applications

Interface with rigid arm configurations

Eliminates vertical overtravel

The i mounts to most standard trolleysand rail profiles and allows seamless endeffector interface. It can also beconfigured with the Stanley i tocreate multi-axis Intelligent Assist Device(IAD) systems.

For added versatility, the i can also beconfigured to provide vertical lift for rigidarm systems.

The responsive slide handle allowsstopping precisely in the intendedposition, with no noticeable delay.

Lift

Trolley

Lift

Greater productivity

Error-proofing

Faster cycle times are achieved with thesystem’s speed, float mode, and semi-automation features, allowing operatorsto accomplish more in a shorter period oftime. The i offers continuous, variable-speed lift control with a maximum speedup to 5 times faster than speeds offeredby standard hoists.

automatically comparesactual load weight to an expected value.By identifying loads that are either underor over the expected weight, operatorscan easily and reliably identify errors thatmay have occurred in assembly orpacking operations.

Lift

Features

Slide or Pendant Handle

Float Mode

Choose from two handle configurationsfor direct, hands-on or proportional push-button

Featuring an advanced patented floatmode, the i s:

• Hands-on (“float mode”) fine tuning ofload position.

• Movement of loads without the need topush buttons from the central controlposition—shaving seconds from cycletimes.

control.

• Automatic mass estimation—no need topush a button each cycle.

Easily programmable virtual limits preventload damage and enhance productivity byconstraining up/down movement.

Valuable feature for analyzing real-timeconditions of the IAD system.Examples include:

• Maintenance—tracking preventativemaintenance schedules

• Error-proofing—comparing actual loadweight against an expected value

• Optional Ethernet connection—enables communication with user plantinformation systems

Permits drift-free payload changes, idealfor dumping applications.

The i is completely self-contained, withon-board controls requiring only 120 V ACpower.

Lift enable

Virtual limits

Access to system information

Locked position

Self-contained unitLift

Additional system features

• Precision set-down

• Speed reduction points

• Load interlock

• Odometer function

• Anti-recoil

• Capacity overload protection

• E-Stop


500 lb. Cap.

7

NEW500 lb.

Capacity

Unit

Now

Available

Are upper

extremity strains and

injuries increasing

in your plant?

End Truck

Bridge Crane

HubAllows programming of systemparameters such as speed,acceleration, sensitivity, andvirtual limits.

Virtual andSurfaces LimitsConstrain trolley movementalong the bridge/runway,guide operator motion,prevent overtravelor collision.

End Truck

Vertical Lift DeviceEasily interfaces withi or air balancers.Lift

Cable Angle SensorSenses operator intent with reliable,non-contact sensor (patented).

Does your

ergonomic assist

equipment slow

operators down?

Installation on existingor new rails from allmajor manufacturers.

Do you need more

control of your process

to improve quality?

Do you need to

add error proofing?

Unmatched Productivity. Unparalleled Ergonomics.With Stanley's new i for enclosed and patented track rail systems, moving loads with large unwieldy bridgecranes is now possible with greater speed and precision than ever before. The system masks the momentum andinertia of the overhead crane, greatly reducing the starting-and-stopping strain that causes most operators to abandonthe equipment and perform the task manually.

The servo-driven i is the highest performance drive system ever created for enclosed and patented track railsystems. The system utilizes a collection of intent sensors, such as the cable angle sensor, that measure humanintent and command the i system to respond as if it was an extension of the human operator.

Providing easy mounting with all conventional rail profiles (both new and existing installations), quick programmabilityfrom its central hub, semi-automation, and much more, the i helps get the highest performance and productivityfrom overhead rail systems.

Trolley

Trolley

Trolley

Trolley

Intelligent Rail System


Specify 2 (3 runway)or 3 (2 runway)configurations.

iTrolleyiTrolley

8

®

®


Benefits

Monorail or bridge crane applications

Versatility

Depending on the application, a one, two, orthree-trolley system can be installed. Using thei y for horizontal movement, vertical liftingcan be accomplished with a Cobotics i orstandard air balancer.

TrolleLift

i y interfaces with both cable-based andrigid arm lift assist systems.

•

•

•

Trolle

Greater ProductivityFast, accurate movements with improvedergonomics and semi-automation helpoperators work faster, for longer periods oftime. Tests show an average of 57% greaterproductivity compared with manual systems.

Reduced Strain

Eliminates Overtravel

Semi-automation

Non-contact Cable Angle Sensor

Programmable Hubwith RS232 interface

By masking the inertia and momentum of theoverhead load, the i greatly reduces thepush/pull forces as well as the energy requiredto perform each cycle.

tops precisely on the intended mark,eliminating the productivity losses associatedwith multiple repositioning.

With commands such as “return to home”,the i can automate portions of theload movement process, freeing operators toperform secondary tasks.

This exclusive patented sensor detects theoperator's movement in the intended directionand provides immediate power assist.Eliminating the need to push multiple buttons,the operator simply grasps the loadand pushes it in the direction they want totravel. The non-contact cable angle sensormeasures the proportional deflection ofthe cable and the intelligent systemresponds as quickly as the operator moves.

As the high-speed communication linkand main operator interface, the Huballows the user to:

Program and switch between operatorpreferences for speed, acceleration,and sensitivity.

Perform data collection for QA/QC,error correction, and tracking.

Trolley

Trolley

i

Programmable from the Hub, virtual limitsprevent load damage and enhanceproductivity.

The i drive is easily disengaged forservice or for manual backup.

Easily set up, configure, and programthe system with a laptop.

Trolley s

Trolley

Features

Virtual Limits

Disengage Function

i SpecificationsTrolley

Maximum Velocity:

Maximum Acceleration:

±2.0 m/sec (393 ft/min) at 300 lbs.per trolley

±0.4 G peak acceleration at 300 lbs.per trolley

CES,

Primary Power:

Current Draw:

Maximum Trolley Load Capacity:

Maximum Travel:

Maximum Bridge Length:

Compatible with the following:

120VAC

20 amps max (for 3 trolley system)

1000 lbs. (454 kg)

Unlimited runway travel

Up to 9m (30ft) bridge length

Stanley, KBK, Knight, Unified,Zimmerman/IR,Patented Track & I-Beam

i increases productivity by reducingpush/pull forces and amplifying strength.Trolley


60

40

20

0

-20

-40

-60

-800 2 4 6

forc

e(lb

s)

time (sec)

60

40

20

0

-20

-40

-60

-800 2 4 6

forc

e(lb

s)

time (sec)

315 lbs225 lbs180 lbs

135 lbs90 lbs

Manual Bridge Crane

Productivity

Res

ults

may

vary

depe

ndin

gon

appl

icat

ion

57%increase

Manualtrolley iTrolley

7

11

cycl

esp

erm

inu

te

9

Effectively Minimizes the Force Required to Start/Stop a Load.

Average 77%lower force to

stop load.

load

®

®

Intelligent Arm System

Do you need highly

responsive power

assist in your arm

application?

Are you having

trouble meeting your

productivity goals?

Does your

ergonomic assist

equipment slow

operators down?

Are upper

extremity strains and

injuries increasing

in your plant?

A Better, More Powerful Ergonomic Arm SolutionGain high productivity while minimizing operator injury, with the ultimate power assisted solution, the IntelligentArm system from Stanley.

The system fits applications as automobile seat and door assembly, instrument panel install,engine/transmission and drive train assembly, handling of large sheet metal, and movement of parts in and out of racks.

Using Cobotics' i components, the System easily integrates with most conventional rail profiles andhelps realize the highest performance from manipulator arms.

Rail

Trolley

Cobot

RailCobot

Grip RailCobot

RailCobo

RailCobot

The system offers the most intuitive power assist technology available with automation features such as virtuallimits and line tracking. The system delivers greater productivity as compared to manual methods. When the operatorbegins to push on the i , the actuators provide instant power assist in the desired direction at 90% lessergonomic force.

t such

End Truck

Installation on existing or new railsfrom all major manufacturers.

Bridge Crane

HubAllows programming of systemparameters such as speed,acceleration, sensitivity, andvirtual limits.


iGripMulti-axis

intent sensor

End Truck

®

RailCobot

Power RotateProvides additional axis ofpower-assist and control.

™



Vertical MovementCan be achieved with pneumaticor electrical cylinder.

10

® ®


11

Res

ults

may

vary

depe

ndin

gon

appl

icat

ion

93%decrease

lbs.

Cobotics 5 lbs. Manual 77 lbs.

11


i interfaces with existing or newmanipulator arms

Monorail or bridge crane applications

Trolley

The i System can add power assist toexisting or new manipulator arms. Thisaddition maximizes productivity, quality andergonomics for arm applications.

Using the i for horizontal movement,vertical lifting can be accomplished with apneumatic or electric cylinder, Cobotics i orair balancer. The System also integratesseamlessly with end effectors.

Trolley

Trolley

Lift

Benefits

Intuitive power assist

Reduced strain and improved ergonomics

Eliminates overtravel

The System providesinstantaneous power assist in response tooperator movements. It uses "intent sensors"to track operator motions without noticeabledelay. This dramatically reduces the forcesthat the operator must apply.

By masking the inertia and momentum of thearm and load, the i System greatlyreduces the push/pull forces as well as theenergy required to perform each cycle.

i stops precisely on the intendedmark, eliminating the productivity lossesassociated with repositioning.

RailCobot

Trolley

Trolley

Increases productivity

Semi-automation

Error proofing

Fast, accurate movements with improvedergonomics and semi-automation helpoperators meet the ever increasing need toreduce cycle time.

Using commands such as line tracking and"return to home," the i can automateportions of the load movement process,freeing operators to perform secondary tasks.Automated functionality includes:

Line tracking capability in which thesystem is synchronized with a line orconveyor, allowing operator and line tomove together easily.

• Network capable for communicationwith plant information systems.

Virtual surface capability enables theto pick only from a selected rack,

thus preventing the use of incorrect parts.

Trolley

RailCobot

•

Features

Intent sensors

Virtual surfaces and limits

I/O & communications capability

follow the direct movementof the operator to provide power assist withno physical strain. The sensors quantify thespeed and direction of motion that theoperator requires. Proprietary algorithmsthen direct the system's movement.

enable theprogramming of virtual surfaces, paths orfunnels to ensure swift, efficient movementswithout collision or load damage.

The Cobotics system can interface with plantcontrol systems or PLCs to provide additionalfunctionality such as error proofing a task ortransmitting system status to themaintenance group.

11

Moving Conveyor

Virtual SurfaceIAD with operator

Intelligent rail system

Quality: Virtual Surfaces Reduce Collisions

ErgonomicsRailCobot systems reduce push/pull force

© 2005 THE STANLEY WORKS, ALL RIGHTS RESERVED

CD0505

STANLEY in a notched rectangle design, the Cobot logo,and are trademarks of The Stanley Works

or its affiliates in the United States and elsewhere.


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WEB ADDRESS

STANLEY ASSEMBLY TECHNOLOGIES


STANLEY WORKS Ltd. (FRANCE)

STANLEY GERMANY, Inc.

STANLEY TOOLS S.r.l. (ITALY)


THE STANLEY WORKS SHANGHAI REPRESENTATIVE OFFICE


5335 Avion Park DriveCleveland, Ohio 44143-2328USA Tel: +1 (440) 461-5500Fax: +1 (440) [email protected]

Applications and Productivity Center5800 Enterprise CourtWarren, Michigan 48092USA Tel: +1 (586) 393-1100Fax: +1 (586) 393-1200Toll Free Service: (877) 787-7830Toll Free Sales: (877) 709-8006

Outils Portatifs et Systemes d'AssemblageZone Imoparc bat Loire 4, 78190 Trappes, FranceTel: +33 (1) 3050 9100Fax: +33 (1) 3051 0708

Frankfurter Strasse 74D-64521 Gross-Gerau, GermanyTel: +49 (0) 6152 8052-0Fax: +49 (0) 6152 [email protected]

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Room 1908, Shanghaimart Tower,2299 Yan An Road WestShanghai 200336, ChinaTel: 011-86-21-3208-4550Fax: 011-86-21-6236-0191

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